Transmission Replacement

REPLACEMENT
1. SEPARATE BATTERY NEGATIVE TERMINAL
2. REMOVE SHIFT LEVER KNOB SUB-ASSEMBLY

(a) Remove the shift lever knob sub-assembly.

(b) Remove the floor shift shift lever knob sub-assembly.

3. REMOVE CONSOLE UPPER PANEL GARNISH NO.1
4. REMOVE CONSOLE UPPER PANEL GARNISH NO.2
5. REMOVE CONSOLE PANEL UPPER ASSEMBLY

6. REMOVE TRANSFER HIGH & LOW SHIFT LEVER ASSEMBLY
(a) Using needle nose pliers, remove the snap ring and pull out the transfer high & low shift lever assembly from the transfer assembly.
7. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
8. REMOVE ENGINE UNDER COVER ASSEMBLY REAR

9. REMOVE FRONT SUSPENSION MEMBER BRACKET
(a) Remove the 4 bolts and front suspension member bracket.
10. REMOVE FRONT SUSPENSION MEMBER BRACKET LH
(a) Remove the 4 bolts and front suspension member bracket LH.
11. DISCONNECT OXYGEN SENSOR
12. REMOVE EXHAUST PIPE ASSEMBLY
13. REMOVE PROPELLER SHAFT ASSEMBLY FRONT
14. REMOVE PROPELLER SHAFT ASSEMBLY
15. DRAIN AUTOMATIC TRANSMISSION FLUID
(a) Remove the drain plug, gasket and drain ATF.
(b) Install a new gasket and drain plug.
Torque: 28 Nm (285 kgf-cm, 21 ft-lbf)
16. REMOVE FRONT SUSPENSION MEMBER BRACKET LH

(a) Remove the 2 bolts and 2 clamps.

(b) Using SST, disconnect the oil cooler outlet tube No.1.
SST 09023-12701
17. DISCONNECT OXYGEN SENSOR
(a) Using SST, disconnect the oil cooler outlet tube No.1.
SST 09023-12701

18. DISCONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Remove the nut and clip, disconnect the transmission control cable assembly from the transmission control cable bracket.

19. SUPPORT AUTOMATIC TRANSMISSION ASSEMBLY
(a) Support the transmission with a transmission jack.

20. REMOVE FRAME CROSSMEMBER SUB-ASSEMBLY NO.3
(a) Remove the 4 bolts on the frame crossmember sub-assembly No.3.
(b) Remove the 4 nuts, 4 bolts and frame crossmember sub-assembly No.3.

21. DISCONNECT CONNECTOR
(a) Tilt down the transmission.

NOTICE: Take care so that the cooling fan does not come in contact with the fan shroud.

(b) Disconnect the park/neutral position switch connector.
(c) Disconnect the transmission wire connector.
(d) Disconnect the 2 speed sensor connectors.
(e) Disconnect the speedometer sensor connector.
(f) Disconnect the indicator No.1 switch connector. (Low)
(g) Disconnect the indicator No.2 switch connector. (Neutral)
(h) Disconnect the indicator No.3 switch connector. (Diff. lock)
(i) Disconnect the transfer shift actuator connector. (w/ transfer shift actuator)

22. SEPARATE TRANSFER BREATHER HOSE SUB-ASSEMBLY
(a) Separate the transfer breather hose sub-assembly from the transmission assembly.

HINT: The breather hose bracket is tightened together with the transmission housing.

23. DISCONNECT WIRE HARNESS
(a) Remove the 3 bolts and wire harness from the transmission and transfer.
(b) Disconnect the wire harness from the transmission assembly.

24. REMOVE FLYWHEEL HOUSING UNDER COVER
(a) Remove the bolt and flywheel housing under cover.

25. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

(a) Turn the crankshaft to gain access to each bolt.
(b) Hold the crankshaft pulley nut with a wrench and remove the 6 bolts.

26. REMOVE TRANSMISSION CONTROL CABLE BRACKET NO.1
(a) Remove the 2 bolts and transmission control cable bracket.
27. REMOVE TRANSFER ASSEMBLY

28. REMOVE ENGINE MOUNTING INSULATOR REAR NO.1
(a) Remove the 4 bolts and engine mounting insulator rear No.1.
29. REMOVE TORQUE CONVERTER CLUTCH ASSEMBLY
30. INSPECT TORQUE CONVERTER CLUTCH ASSEMBLY
SST 09350-32014 (09351-32020)

31. INSTALL TORQUE CONVERTER CLUTCH ASSEMBLY
(a) Install the torque converter clutch to the automatic transmission.

(b) Using calipers and a straight edge, measure dimension A between the transmission and the end surface of the drive plate.

(c) Using calipers and a straight edge, measure the dimension B shown in the illustration and check that B is greater than A measured in (b).
Standard: A + 1 mm or more

32. INSTALL ENGINE MOUNTING INSULATOR REAR NO.1
(a) Install the engine mounting insulator rear and 4 bolts to the automatic transmission.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)

33. INSTALL TRANSFER ASSEMBLY

34. INSTALL TRANSMISSION CONTROL CABLE BRACKET NO.1
(a) Install the transmission control cable bracket No.1 with 2 bolts.
Torque: 25 Nm (255 kgf-cm, 19 ft-lbf)

35. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

(a) Install the automatic transmission and 10 bolts to the engine.
Torque:
17 mm head: 71 Nm (720 kgf-cm, 53 ft-lbf)
14 mm head: 37 Nm (380 kgf-cm, 27 ft-lbf)

(b) Install the 6 torque converter clutch mounting bolts.
Torque: 48 Nm (490 kgf-cm, 35 ft-lbf)

HINT: First install black colored bolt and then the 5 bolts.

36. INSTALL FLYWHEEL HOUSING UNDER COVER
(a) Install the flywheel housing under cover and bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)

37. CONNECT WIRE HARNESS
(a) Install the wire harness with the bolt.
Torque: 8.0 Nm (83 kgf-cm, 71 in.-lbf)

38. INSTALL TRANSFER BREATHER HOSE SUB-ASSEMBLY
(a) Install the transfer breather hose sub-assembly.

HINT: The breather hose bracket is tightened together with the transmission housing.

39. CONNECT CONNECTOR
(a) Connect the speed sensor SP2 connector.
(b) Connect the transmission wire connector.
(c) Connect the park/neutral position switch assembly connector.
(d) Connect the temperature sensor connector.
(e) Connect the speedometer sensor connector.
(f) Connect the indicator No.1 switch connector. (Low)
(g) connect the indicator No.2 switch connector. (Neutral)
(h) Connect the indicator No.3 switch connector. (Diff. lock)
(i) Connect the transfer shift actuator connector. (w/ transfer shift actuator)

40. INSTALL FRAME CROSSMEMBER SUB-ASSEMBLY NO.3
(a) Install the frame crossmember sub-assembly No.3 with 4 bolts and 4 nuts.
Torque: 72 Nm (735 kgf-cm, 53 ft-lbf)
(b) Install the frame crossmember sub-assembly No.3 with 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)

41. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
(a) Install the nut and clip on the transmission control cable assembly.
Torque: 12 Nm (122 kgf-cm, 9 ft-lbf)

42. INSTALL OIL COOLER OUTLET TUBE NO.1
(a) Temporarily install the oil cooler outlet tube No.1.
(b) Temporarily install the oil cooler inlet tube No.1.

(d) Using SST, tighten the oil cooler outlet tube No.1.
SST 09023-12701
Torque: 34 Nm (346 kgf-cm, 25 ft-lbf)

43. INSTALL OIL COOLER INLET TUBE NO.1
(a) Using SST, tighten the oil cooler inlet tube No.1.
SST 09023-12701
Torque: 34 Nm (346 kgf-cm, 25 ft-lbf)

44. INSTALL FRONT SUSPENSION MEMBER BRACKET LH
(a) Install the front suspension member bracket LH with 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
45. INSTALL FRONT SUSPENSION MEMBER BRACKET
(a) Install the front suspension member bracket with 4 bolts.
Torque: 33 Nm (336 kgf-cm, 24 ft-lbf)
46. INSTALL PROPELLER SHAFT ASSEMBLY
47. INSTALL PROPELLER SHAFT ASSEMBLY FRONT
48. ADJUST SHIFT LEVER POSITION
49. INSTALL EXHAUST PIPE ASSEMBLY
50. INSTALL OXYGEN SENSOR
51. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)
52. INSTALL ENGINE UNDER COVER ASSEMBLY REAR
Torque: 29 Nm (296 kgf-cm, 21 ft-lbf)

53. INSTALL TRANSFER HIGH & LOW SHIFT LEVER ASSEMBLY
(a) Using needle nose pliers, install the transfer high & low shift lever assembly with snap ring.

HINT: Apply MP grease to the transfer shift lever.

54. INSTALL CONSOLE PANEL UPPER ASSEMBLY
55. INSTALL CONSOLE UPPER PANEL GARNISH NO.2
56. INSTALL CONSOLE UPPER PANEL GARNISH NO.1
57. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY
(a) Install the shift lever knob on the shift lever.
(b) Install the floor shift shift lever knob on the shift lever.
58. ADD AUTOMATIC TRANSMISSION FLUID
59. INSPECT AUTOMATIC TRANSMISSION FLUID
60. INSTALL BATTERY NEGATIVE TERMINAL
61. INSPECT SHIFT LEVER POSITION
62. CHECK FOR EXHAUST GAS LEAKS